Impact of welding conditions and microstructural variations on weld bead configurations in duplex stainless steel AISI 2205 weldments

Abstract This study investigates how welding parameters affect weld bead geometry and microstructural characteristics of duplex stainless steel (DSS) using shielded metal arc welding (SMAW), highlighting the importance of process control for weld quality. The work examines heat input, controlled by welding current and electrode type, on bead geometry and microstructure. Welding was performed under direct current with electrode positive polarity (DCEP) at 90 and 110 A, with a constant voltage of 23.0 V, using DSS electrodes E1, E2, and C. Weld bead height and width were measured, and surface topography was analyzed with a stereomicroscope. High heat inputs of 1.52 and 1.51 kJ/mm produced wide weld beads exceeding 12.00 and 11.5 mm, while bead heights remained 1.60 and 2.21 mm. Microstructural analysis confirmed ferrite and austenite phases, and proper heat input promoted good fusion, whereas excessive or insufficient heat input impaired bead geometry and fusion quality. Graphical abstract